Help! I've overextended my axle! What to do?

[RotBoxCorolla]

I have a 1991 Toyota Corolla (4AFE engine) with 188K miles. I needed to change my front brakes, so I raised the front on jackstands. I thought I was being nice, and decided to change the driver's side axle (outer boot was torn, and I figured that was what made a little noise on the turns). I got a new axle from Napa. I was feeling generous, so I even bought lower ball joints & motor mounts!

I didn't think things were going too badly, as I got the new axle in. I saw a little blurb, in that miniscule print, about not overextending the axle, and making sure it was supported, and I thought we were talking about overflexing it, and it was fine. I put the axle back in the hub loosely, and was trying to line up the new ball joint, but it didn't seem to allow me to get the extra half inch or so to line up the holes in the control arm/ball joint.

That's when I happened to notice the inner boot was really stretched out and realized the CV joint must be apart in there. I was not pleased. I tried to turn the axle, to see if it would go back in (since it didn't from the current position), but it didn't make any difference. Since it was probably 11 pm or so, I just moped back into the house, and held back the tears.

When I look at it with fresh eyes this weekend, what are my chances of coming out ahead in this game? Is there a trick to getting it right again? If it can get back together, should I then worry about the boot failing, or damage to the axle? I haven't forced anything, so I'm keeping my fingers crossed. I have plenty of tools (it seemed to be going pretty easily at first) and am only 90% moron.

In the meantime, I guess I'll be under my '86 Vanagon, '83 CJ-7, '77 moped, '71 snowblower, 'whoknowswhat Gravely, ... *sigh* it's just never easy around here As you can see, I'm used to overextended myself...but never my axle! (how embarrassing)

Thanks to anyone who takes pity on me!

[root]

If you didn't force anything, I'd say you'll prob be ok. The joint seperated and the shaft probably rotated inside the boot so the three lobed rollers isn't aligned with the cup anymore. Rotate the shaft a little while keeping the cup at the transaxle side still, or vice versa. Hopefully it goes back in to where it was before. And hopefully the boot isn't torn. New boots are pretty supple so prob ok.

[freakinbox]

I was doing my driver side ball joint and got to find out the axels are really only sitting there and ended up pulling it out. I just shoved it back in, so I should think you'll be alright, unless like said above the boot is torn

[RotBoxCorolla]

Encouraged by your words, I went out to try again. I couldn't do much with the axle flexed, so I removed the axle from the hub (hadn't tightened it down yet) - then within maybe 5 minutes, it was all set. I put the new ball joint in on that side, and went to torque the nuts/bolts to 105 ft-lbs, and they just kept spinning (wasn't even close to that torque because it really wasn't tight at all). So, I had to use a cutting wheel to cut off those nuts, and bang out the bolts (). Ended up using the old bolts, which worked fine. Guess I should have bought the $63 ball joints, instead of the $17 ones they came up with when I told Napa they were out of their minds. If the ball joints themselves didn't look all right, and if Napa weren't closed, I would have smacked 'em around a bit to get a better price today on the others.

Looks like that rotor got scored by the rivets on one side (inside). Those rotors only had one set of pads on them (checked thickness, and it's within specs), so they're staying until next time - tried to sand the bad side a little smoother. Hope it doesn't chew through the new pad too fast, but I'll risk it.

The other side's old ball joint was actually worse (who knew- I was just being proactive here), and the bolts were grade 8.8, but I didn't get them to 105 ft-lbs (thought they might be looking to strip soon - they're pretty close). Used one original bolt, and that's in there at the right torque. You KNOW I wasn't gonna let that axle get overextended!

So, maybe I should eat something, but I'm goin' back in! Time to change at least one motor mount (saw it was cracked, and that's probably why I put so many exhausts on this car grrr). I pried the engine, and it really had a lot of front-to-back motion. Then, I'll drive it this week to remember why I'm doing all this. Next weekend, I hope those wheel cylinders come out easily, and I'll use the spring set I bought (had to replace the shoes many moons ago, but one spring was distorted - it went back in place, because, once again, every place was closed). Tire treads seem low - didn't I just buy these tires?

Hope we make it up to Canada in October (and maybe even back!)

[retiredat44]

new rotors are only about $20.00 why didn't you just replace it?

[RotBoxCorolla]

You know, I thought I paid a lot more than that at Napa last time, but I may be wrong. I would have liked to have them just cut it slightly to clean it up, but I think I remember they didn't cut that rotor, just replaced it. Then I would have said, well, I'd better get the other side too. Maybe it's the few hundred I just dumped into this heap of bolts (maybe less, depending on what mounts I use). I have to run from vehicle to vehicle and pick the biggest problems - that's the way it works around here

Don't worry, I'll be driving it during the week, and if there's any indication of a problem when I look at it, I'll just change it - I can't take the shame!

Now I gotta figure out how to squeeze the rear transaxle mount out (didn't quite make it when I raised it slightly with the floor jack). Might have to take the bracket off *sigh* here we go again...I guess it'll wait until tomorrow...